AC Hose - Low Side

This procedure involves replacing the low-side AC hose on a 2022 Rivian EDV 500, requiring AC system evacuation, hose replacement, and recharging.

Warnings

Tools required

Parts

• AC low-side hose assembly × 1 — Use OEM specification
• O-ring kit for AC fittings × 1 — Use OEM specification
• PAG oil for electric vehicle AC system × 1 — Use OEM EV-compatible PAG oil
• R-1234yf refrigerant × 1 — As needed based on system capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes
3. Verify high-voltage system is de-energized following Rivian service procedures
4. Allow AC system to equalize to ambient temperature if recently operated
5. Connect AC recovery machine and identify refrigerant type to confirm R-1234yf
6. Record system refrigerant charge amount during recovery for proper refill
7. Ensure work area is well-ventilated and free of ignition sources

Procedure

1. 1

   Recover AC refrigerant
   Connect the AC recovery machine to both high and low-side service ports. Follow machine instructions to fully recover all refrigerant from the system. Record the amount recovered for recharging reference. Verify system pressure reads 0 PSI on both gauges before proceeding.
2. 2

   Access low-side hose routing
   Remove underbody panels or wheel well liner as necessary to access the low-side AC hose routing from the evaporator to the compressor. On the EDV 500, this typically requires removing the driver-side front wheel well liner. Remove fasteners and carefully pull liner away to expose hose routing.
3. 3

   Document hose routing
   Take photos of the existing hose routing, noting all mounting clips, brackets, and clearances. Pay special attention to how the hose routes near the electric drive unit and high-voltage cabling to ensure proper clearance during reinstallation.
4. 4

   Disconnect low-side hose at evaporator
   Locate the low-side hose connection at the evaporator inside the engine bay area. Use appropriate hose disconnect tool to release the quick-connect fitting. If using threaded fittings, support the evaporator fitting with a backup wrench while loosening the hose connection nut. Cap the evaporator port immediately to prevent contamination.
5. 5

   Disconnect low-side hose at compressor
   Locate the low-side hose connection at the electric AC compressor. Support the compressor port fitting with a backup wrench and carefully loosen the hose connection. Remove the hose and immediately cap both the compressor port and hose end to prevent moisture and debris entry.
6. 6

   Remove hose from mounting brackets
   Release the low-side hose from all mounting clips and brackets along its routing path. Note the position and orientation of each clip for proper reinstallation. Remove the old hose from the vehicle, being careful not to damage surrounding components.
7. 7

   Inspect and prepare new hose
   Inspect the new low-side hose assembly for damage and verify it matches the original routing configuration. Install new O-rings on all fittings, lubricating them lightly with the appropriate EV-compatible PAG oil. Do not reuse old O-rings.
8. 8

   Route and install new hose
   Route the new low-side hose following the documented path from the previous hose. Ensure proper clearance from high-voltage components, sharp edges, and heat sources. Secure the hose in all mounting clips and brackets, ensuring it matches the original routing to prevent vibration and chafing.
9. 9

   Connect hose to compressor
   Remove the cap from the compressor port and hose fitting. Install the hose to the compressor connection, ensuring the O-ring is properly seated. Hand-tighten the fitting, then use a torque wrench and backup wrench to tighten to specification. If no specification available, tighten securely without over-torquing the aluminum fittings.
10. 10

    Connect hose to evaporator
    Remove the cap from the evaporator port and hose fitting. Connect the low-side hose to the evaporator, ensuring proper O-ring seating. For quick-connect fittings, push firmly until an audible click is heard and verify connection by pulling on the hose. For threaded fittings, tighten properly with backup wrench.
11. 11

    Evacuate AC system
    Connect the vacuum pump to the AC service ports. Evacuate the system to at least 29 inches of mercury vacuum. Hold vacuum for minimum 30 minutes to verify system integrity and remove any moisture. If vacuum does not hold, there is a leak that must be addressed before charging.
12. 12

    Charge AC system
    Using the AC machine, charge the system with the recorded amount of R-1234yf refrigerant (or manufacturer specification if different). Add the appropriate amount of EV-compatible PAG oil as specified by the hose manufacturer or Rivian service information. Monitor pressures during charging to ensure proper fill.
13. 13

    Leak test system
    With the system charged, use an electronic R-1234yf leak detector to check all connections, particularly the newly installed hose fittings at both the compressor and evaporator. If UV dye was added, use UV light to inspect for leaks. Address any leaks found before proceeding.

Reassembly

1. Reinstall all underbody panels and wheel well liners with original fasteners
2. Reinstall wheel if removed and torque lug nuts to specification
3. Reconnect 12V battery negative terminal
4. Verify all tools and parts have been removed from vehicle

Verification

• Start vehicle and activate AC system to maximum cooling
• Verify compressor engages and runs smoothly without unusual noise
• Check that low-side pressure reads 25-40 PSI and high-side reads 150-250 PSI at idle with AC on max (ambient temperature dependent)
• Verify cold air is being produced at dash vents, checking vent temperature with thermometer (should be 40-50°F below ambient)
• Inspect all new hose connections for signs of refrigerant leakage or oil seepage
• Verify hose routing has proper clearance and is not contacting any components during operation
• Test drive vehicle and verify AC performance remains consistent under various operating conditions

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